Tool, method and system for well services

ABSTRACT

An oilfield tool, method and system are provided to run casing and cement the casing in place. The oilfield tool includes a casing running tool, a dynamic device launching tool, and a swivel adapted to engage a fluid supply line. The method includes configuring an oilfield tool, running casing into a borehole using the oilfield tool, and cementing the casing into the borehole using the oilfield tool. The system includes an oilfield tool that includes a casing running tool, a side entry dynamic device launcher connected to the casing running tool and adapted to launch dynamic devices, and a swivel connected to the side entry dynamic device launcher and comprising a fluid supply interface. In addition, the system includes a sealant supply device, and a borehole fluid supply device.

BACKGROUND

The following descriptions and examples are not admitted as being priorart by virtue of their inclusion in this section.

Many operations are performed in providing well services to create asafe and functioning oil well. For example, some oil wells use casingthat is cemented in place in the borehole. This casing may be run tokeep a borehole from collapsing or to satisfy environmental or safetyregulations for the drilling site. However, running casing has beenperformed using a specific rig tool, sometimes referred to as a CasingRunning Tool (CRT). This CRT may be replaced with another rig toolconfigured to cement the casing in place. Changing from one rig tool toanother involves coordination, planning, and time to remove the firstrig tool and then set up and run the second rig tool. Changing from onerig tool to another also requires the use of very expensive rig time,potentially affecting the overall profitability of the well.

SUMMARY

This summary is provided to introduce a selection of concepts that arefurther described below in the detailed description. This summary is notintended to identify key or essential features of the claimed subjectmatter, nor is it intended to be used as an aid in limiting the scope ofthe claimed subject matter.

In accordance with an embodiment, an oilfield tool is provided thatincludes a Casing Running Tool (CRT) adapted to run casing into aborehole. In addition, the oilfield tool may include a dynamic devicelaunching tool adapted to launch dynamic devices and a swivel adapted toengage a fluid supply line. The oilfield tool is used to run casing andcement the casing into the borehole without requiring modification ofthe oilfield tool configuration. Dynamic devices launched by the dynamicdevice launching tool traverse through the CRT and alter theircircumferential configuration to engage an inner surface of the casingand to separate a sealant (e.g., a cement slurry, a resin, among others)provided via the fluid supply line from other borehole fluids.

In accordance with another embodiment, a method for oilfield boreholepreparation is provided that includes configuring an oilfield tool. Theoilfield tool may include a CRT, a dynamic device launching tool coupledto the CRT and adapted to launch dynamic devices, and a swivel adaptedto engage a fluid supply.

The method may further include running casing into a borehole using theoilfield tool and cementing the casing into the borehole using the sameoilfield tool. The dynamic devices traverse via the CRT and, in someapplications, function to separate a sealant from other borehole fluids.

In accordance with another embodiment, an oilfield system for runningand cementing casing is provided. The oilfield system may include anoilfield tool comprising a CRT, a dynamic device launching tool coupledto the CRT and adapted to launch dynamic devices, and a swivel coupledto the dynamic device launching tool and coupled to a fluid supplyinterface. The system may further include a sealant supply device and aborehole fluid supply device.

The oilfield system is configured to run casing into a borehole. Asealant is introduced from the sealant supply device via the fluidinterface. The sealant follows a first dynamic device traversing theCRT. The first dynamic device subsequently engages an innercircumference of the casing.

A borehole fluid is introduced from the borehole fluid supply device viathe fluid supply interface via the fluid interface. The borehole fluidfollows a second dynamic device traversing the CRT. The second dynamicdevice subsequently engages an inner circumference of the casing. Anincreasing pressure may rupture the first dynamic device, providingsealant to the annulus surrounding the casing.

Other or alternative features will become apparent from the followingdescription, from the drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Certain embodiments will hereafter be described regarding theaccompanying drawings, wherein like reference numerals denote likeelements. It should be understood, however, that the accompanyingdrawings illustrate only the various implementations described hereinand are not meant to limit the scope of various technologies describedherein. The drawings are as follows:

FIG. 1 is a schematic of an oilfield tool and borehole with an outermostlayer of casing cemented in place, according to an embodiment of thedisclosure;

FIGS. 2A-2C are schematics representing exemplary stages of a cementingprocess using the same oilfield tool for running in casing andcementing, in accordance with an embodiment of the disclosure;

FIGS. 3A-3D are exemplary flowcharts of operational actions for using anoilfield tool for running in casing and cementing the casing in place,in accordance with an embodiment of the disclosure;

FIGS. 4A-4B are schematics of an exemplary dynamic device in reduceddiameter and expanded diameter form, in accordance with anotherembodiment of the disclosure; and

FIG. 5 is a schematic of an oilfield tool in accordance with anotherembodiment of the disclosure.

DETAILED DESCRIPTION

Reference throughout the specification to “one embodiment,” “anembodiment,” “some embodiments,” “one aspect,” “an aspect,” or “someaspects” means that a particular feature, structure, method, orcharacteristic described in connection with the embodiment or aspect isincluded in at least one embodiment of the present disclosure. Thus, theappearance of the phrases “in one embodiment” or “in an embodiment” or“in some embodiments” in various places throughout the specification arenot necessarily all referring to the same embodiment. Furthermore, theparticular features, structures, methods, or characteristics may becombined in any suitable manner in one or more embodiments. The words“including” and “having” shall have the same meaning as the word“comprising.”

Moreover, inventive aspects lie in less than all features of a singledisclosed embodiment. Thus, the claims following the DetailedDescription are hereby expressly incorporated into this DetailedDescription, with each claim standing on its own as a separateembodiment.

Production of hydrocarbons or other fluids from geological formationsrequires the use of several technologies. Referring generally to FIG. 1,an exemplary schematic cross-section of an oil well operation is shownwith an outer borehole 120 and an inner borehole 125 located in thesurface 110 of an oil field. The oil field can either be located on landor undersea. Teachings of the current disclosure should not be limitedto one of these two applications and/or locations.

To prevent the collapse of the boreholes 120 and 125 among otherreasons, an outer casing 130 and an inner casing 135 have been run intothe boreholes. Although two casings 130, 135 have been shown, for thepurposes of description only the outer casing 130 has been cemented intothe outer borehole 120.

Cementing results in the outer sealant 140 filling the outer annulus 150located between the exterior wall of the outer casing 130 and theinterior wall of the outer borehole 120. Cementing the outer casing 130helps in securing the outer casing 130 in place and in sealing theformation surrounding the outer casing 130, and sealing the outerannulus 150, among other reasons.

Generally, both the outer casing 130 and the inner casing 135 arecemented or sealed in place. However, the inner casing 135 has not beendepicted as cemented in order to show in more detail how the outersealant 140, formed during the cementing of the outer casing 130, isdrilled through during the formation of the inner borehole 125. Afterrunning the inner casing 135 into the inner borehole 125, the resultingspace surrounding the exterior of the inner casing 135 and the interiorof the outer casing 130 and the exterior wall of the inner borehole 125is the inner annulus 155.

Running casing and cementing the casing have previously been performedduring separate operations using separate oilfield tools. Changing fromone oilfield tool to another takes up valuable rig time. As furthershown in FIG. 1, an embodiment of the current disclosure uses a singleoilfield tool 100 comprising various components. In one case, a casingrunning tool (CRT) 160, a dynamic device launching tool 170, and aswivel 180 are provided to allow the running of the casing and thecementing of the casing without having to derig one tool and rig upanother.

A swivel 180 is shown in this exemplary embodiment for applications inwhich rotating of the string is required. In other embodiments, a swivel180 may be omitted and the sealant pumped through the top drive. Aside-entry T-piece (not shown) may be used in place of the swivel 180.

The CRT 160 is adapted and configured to run casing. The CRT 160 has aCRT interior passageway 162 that is of a smaller interior diameter thanthe interior diameter of the inner casing 135. In some cases, the ratioof the diameter of the inner casing 135 to the diameter of the CRTinterior passageway 162 of the CRT 160 can be as high as 3 to 1, or 5 to1 in other cases. Of course, these ranges are exemplary and embodimentsof this disclosure may differ as appropriate.

At least in part because of this difference in the interior diameters,the oilfield tool 100 comprises a dynamic device launching tool 170. Inthis exemplary embodiment, the dynamic device launching tool 170comprises a first dynamic device 172, a first dynamic device release173, a second dynamic device 174, and a second dynamic device release175. More dynamic devices or less dynamic devices may be used or held bythe dynamic device launching tool 170 depending upon the application. Insome cases, a dynamic device 172, 174 may be added to the dynamic devicelaunching tool 170 while the oilfield tool 100 is rigged up.

The dynamic devices 172, 174 may be referred to as darts or plugs. Insome applications, dynamic devices 172, 174 function to wipe down andseal against the inner surface of the casing 135. In other applications,the dynamic devices 172, 174 separate diverse types of borehole fluidsfrom one another. Depending upon the application, first and seconddynamic devices 172, 174 may provide sealing, wiping, and separating, orother functions.

The swivel 180 may contain an operational interface 187 (e.g.,electrical, mechanical, or hydraulic, among others) for operating thedynamic device launching tool 170. In some applications, the dynamicdevice launching tool 170 may also be controlled wirelessly (not shown).

The dynamic device launching tool 170 comprises a dynamic deviceinterior passage 176 communicatively coupled to the CRT interiorpassageway 162. A dynamic device 172, 174 released by a dynamic devicerelease 173, 175 traverses through the inner casing 135 via the dynamicdevice interior passageway 176 and the CRT interior passageway 162.

Once within the inner casing 135, the dynamic device 172, 174circumferentially expands from a reduced diameter form to an expandeddiameter form to establish a contacting seal with the inner surface ofthe inner casing 135 (refer to FIGS. 4A and 4B). The dynamic device 172,174 can expand from a reduced diameter form configured to pass throughan initial passageway (e.g., such as the interior passageway of the CRT162) to an expanded diameter form that may substantially seal and/orwipe a circumferential passageway (e.g., such as the interior surface ofthe inner casing 135) that may be approximately three (3) times aslarger or larger than the initial passageway. The expansion of thedynamic devices 172, 174 may be due to the removal of the volumetricconstraints of the initial passageway, or may be due to mechanical,electrical, or flow assisted operation from reduced to full expansion.

Operation of the oilfield tool 100 will be discussed in more detail asfollows.

Turning generally to FIGS. 2A-2C, these exemplary illustrations showsome of the detail surrounding the cementing operation of the oilfieldtool 100, specifically, cementing casing 230 into borehole 220. In FIG.2A, casing 230 has been run to a desired depth in borehole 220 locatedin the surface 210 of an oilfield by oilfield tool 100. Without changingthe oilfield tool 100, first dynamic device 172 was released by firstdynamic device release 173 of the dynamic device launching tool 170.

A sealant (e.g., cement slurry, resin, among others) 245 provided bysealant supply 240 via the fluid inlet 185 of swivel 180 follows thefirst dynamic device 172 into the casing 230. The sealant 240 and firstdynamic device 172 traverse into casing 230 via the dynamic deviceinterior passageway 176 and the CRT interior passageway 162. The firstdynamic device 172 circumferentially expands from a reduced diameter toan expanded diameter in order to substantially separate the sealant 245from a first borehole fluid 252. As the sealant 245 is pumped into thecasing 230, the first borehole fluid 252 is displaced via the annulus240 and removed. FIG. 2A shows a point in time in which the firstdynamic device 172 is travelling downhole inside the casing 230.

At this general time, the second dynamic device 174 is still retained bythe second dynamic device release 175. The second dynamic device 174 maybe provided when the oilfield tool 100 is made up or added to thedynamic device launching tool 170 at some point when required by thecementing operation.

Turning generally now to FIG. 2B, at the instant shown in the figure,the first dynamic device 172 has reached a downhole stopping point nearthe end of casing 230. The second dynamic device 174 has been releasedso as to follow the quantity of sealant 245 necessary to fill theannulus 240 and to cement the casing 230 in place. A second boreholefluid 254 is pumped in via the swivel 180 and fluid inlet 185 andprovided by a borehole fluid supply 250. The second borehole fluid 254may be used to pressure test the casing 230. In addition, the secondborehole fluid 254 may further be used to increase the pressure insideof the casing 230, ultimately rupturing a rupture device 178 located inthe first dynamic device 172.

The rupture device 178 may be a rupture disk or the use of rupture-ablematerial. After exceeding a certain pressure, the rupture device 178ruptures, allowing the sealant 245 to flow into the annulus 240surrounding the casing 230. The second borehole fluid 254 is pumped intothe casing 230 until the sealant 245 is fully distributed within theannulus 240. In some cases, the second borehole fluid 254 will beintroduced into the casing 230 until the second dynamic device 174 isadjacent to the first dynamic device 172, as shown in FIG. 2C.

After the sealant 245 hardens, the first and second dynamic devices 172,174 may be drilled out and an inner casing (not shown) run in andcemented in place. In some cases, multiple internal layers of casing maybe run into a borehole. Depending upon the application, some casing maynot be cemented in place.

Referring generally to FIG. 3A, this figure illustrates a method ofusing the oilfield tool 100. The method is shown using exemplaryflowchart 300, according to an embodiment of the current disclosure. Theflowchart 300 may comprise actions such as configuring an oilfield tool310, running casing with the oilfield tool 320 and cementing the casingwith the oilfield tool 330.

In some embodiments, the action described as configuring an oilfieldtool 310 can be further detailed as comprising providing a CRT 312,providing a dynamic device launching tool 314 and providing a swivel316, as shown in FIG. 3B. As shown in FIG. 3C, running casing with theoilfield tool may include additional actions such as making up casing322 and manipulating casing 324. And still further as shown in FIG. 3D,manipulating casing 324 may include actions such as circulating casing325, reciprocating casing 326, or rotating casing 327.

The oilfield tools may be made up prior to the running of casing. Themaking up of the oilfield tools can be done at the wellsite or prior todelivery to the wellsite. According to some applications, embodiments ofthe oilfield tools may be made up in the following order from bottom totop:

-   -   a. CRT    -   b. dynamic device launching tool comprising first and second        dynamic devices    -   c. swivel—when rotating the string is required, or a side entry        T-piece (not shown) when no rotation of the string is required

The oilfield tool can then be used to pick-up up, run, circulate orreciprocate casing, depending upon the requirements of the application.Casing is made up until the desired depth is reached. Once the casing isat the desired depth, the casing can be circulated, reciprocated orrotated prior to commencing cement operations.

In some embodiments, a sealant hose may be connected to the swivel toallow sealant to be pumped into the well system without passing throughthe top drive. Control and power lines may also need to be connected tothe dynamic device launching tool via the swivel, i.e. with a swivelmechanism for each line comprising a dynamic device (e.g., such as viathe operational interface).

Once circulation is complete, the internal blow out preventer (IBOP)(not shown) may be closed and sealant or other fluids can be pumpedthrough the swivel, dynamic device launching tool and CRT. In otherembodiments, sealant may be pumped directly through the top drive and aside entry T-piece used in place of the swivel. In such an embodiment,the controls for the dynamic device launching tool may be relocated asappropriate.

A first dynamic device (sometimes referred to as a bottom dynamicdevice) may be launched ahead of the sealant to isolate the sealant fromany previous borehole fluids and/or to wipe the internal surface of thecasing wall. This first dynamic device may allow circulation to continueonce the first dynamic device has reached the bottom of the casing.

After the sealant has been pumped into the casing, the dynamic devicelaunching tool can launch a second dynamic device (sometimes referred toas a top dynamic device) that will isolate the sealant from otherborehole fluids following the sealant. The second dynamic device willcreate a pressure tight seal once it has reached the bottom of thecasing, thereby allowing a casing pressure test to be performed.

Either before or after the casing pressure test is complete, floatvalves in the bottom of the casing can be tested by allowing fluid topass backwards through them. Upon completion of the casing pressure testand the float test, the oilfield tool equipment can be rigged down orwracked back. If the oilfield tool is required for further operations,new first and second dynamic devices can be loaded into the dynamicdevice launching tool in readiness for re-use.

Referring generally to FIGS. 4A and 4B, these figures illustrate aschematic of an exemplary dynamic device 400 in reduced diameter form(FIG. 4A) and expanded diameter form (FIG. 4B). In FIG. 4A, the dynamicdevice 400 comprises three or more sets of an inner arm 420 and an outerarm 430. The inner arms 420 may be pivotally coupled with a first block405 and the outer arms 430 may be pivotally coupled with a second block415. The first block 405 and the second block 415 may be resiliently andslidably coupled towards one another via a resilient device 410 (shownin this non-limiting example as a spring in an expanded state).

A distal end of the inner arms 420 may be slidably and pivotally coupledto the body of the outer arms 430. In this embodiment, the coupling isshown as a pin and groove assembly in which the groove 435 is providedin a portion of the outer arm 430. Other mechanisms may be used asappropriate.

The outer arms 430 may interact with a sealing/wiping/separatingcomponent 440 attached around the outer arms 430. In some embodiments,the sealing/wiping/separating component 440 may be a resilient material,fabric, folded structure, or expandable material. In other cases thesealing/wiping/separating component 440 may be composed of multiplecomponent pieces that work together to form an effective, drillablematerial that interacts to seal/wipe the inner circumferential surfaceof the casing or to separate borehole fluids and sealants.

In this illustrative example, in FIG. 4A the resilient device 410 is inan expanded state, providing a contracting force on the first block 405and the second block 410. The dynamic device 400 may be retained in thisreduced diameter form due to the limitations of space provided by theinner passageways of the dynamic device launching tool for example.Other systems or methods of maintaining the dynamic device 400 in areduced diameter form may be used as appropriate. The outer arms 430 andconsequently, portions of the sealing/wiping component 440 may be incontact with the inner surfaces of the inner passageways or storagelocations of the dynamic device launching tool.

When the dynamic device 400 is released, the dynamic device 400transitions to an expanded diameter form to engage the larger innercircumferential area of the casing. The outer arms 430 andsealing/wiping/separating component 440 are all adapted to expand tocontact or otherwise engage the inner surface of the casing.

As seen in FIG. 4B, the resilient device 410 motivates the outer arms430 and sealing/wiping/separating component 440 radially outward. Theouter arms 430 and the sealing/wiping/separating component 440 are thenable to engage the inner surface of the casing substantiallycircumferentially. In some cases, the ratio between the outermostdimension 450 of the contracted dynamic device 400 in reduced diameterform shown in FIG. 4A and the outermost dimension 455 of the expandeddynamic device 400 in expanded diameter form shown in FIG. 4B can be afactor of about three or larger.

Referring generally to FIG. 5, another embodiment of the oilfield tool500 is illustrated. In this exemplary embodiment, an in-line launchingcomponent such as a modified cement head 570 takes the place of thedynamic device launching tool 170. The modified cement head 570 iscoupled to a swivel 580 and CRT 160. The modified cement head 570comprises a first dynamic device 572 and a second dynamic device 574.The modified cement head 570 further comprises a sealant inlet 576 and aborehole fluid inlet 578. In other embodiments in which there is norequired significant rotation of the string, the modified cement head570 may be coupled to a side entry T-piece (not shown) in place of theswivel 580.

After the casing has been run in, a sealant supply engaged to thesealant inlet 576 introduces sealant into the oilfield tool 500. As thesealant flows through the sealant inlet 576, the first dynamic device572 is released ahead of the sealant and travels into the casing belowthe oilfield tool 500. The first dynamic device 572 may provide thefunctionality of separating the sealant from the borehole fluid alreadyin the casing. In some applications, this may be the only function ofthe first dynamic device 572.

When the appropriate amount of sealant has been introduced into thesystem, borehole fluid is provided via the borehole fluid inlet 578. Asborehole fluid is introduced into the oilfield tool 500, the seconddynamic device 574 is released and provides a separation or barrierbetween the sealant and the introduced borehole fluid. As with the firstdynamic device 572, in some applications separation of fluids may be theonly function of the second dynamic device 574.

Elements of the embodiments have been introduced with either thearticles “a” or “an.” The articles are intended to mean that there areone or more of the elements. The terms “including” and “having” areintended to be inclusive such that there may be additional elementsother than the elements listed. The term “or” when used with a list ofat least two elements is intended to mean any element or combination ofelements.

Although only a few example embodiments have been described in detailabove, those skilled in the art will readily appreciate that manymodifications are possible in the example embodiments without materiallydeparting from this disclosure. Accordingly, all such modifications areintended to be included within the scope of this disclosure as definedin the following claims.

In the claims, means-plus-function clauses are intended to cover thestructures described herein as performing the recited function and notonly structural equivalents, but also equivalent structures. Thus,although a nail and a screw may not be structural equivalents in that anail employs a cylindrical surface to secure wooden parts together,whereas a screw employs a helical surface, in the environment offastening wooden parts, a nail and a screw may be equivalent structures.

It is the express intention of the applicant not to invoke 35 U.S.C. §112, paragraph 6 for any limitations of any of the claims herein, exceptfor those in which the claim expressly uses the words ‘means for’together with an associated function.

What is claimed is:
 1. An oilfield tool comprising: a casing runningtool adapted to run casing into a borehole; a dynamic device launchingtool adapted to launch dynamic devices and coupled to the casing runningtool and swivel; a swivel adapted to engage a fluid supply line; whereinthe oilfield tool is utilized to run the casing and cement the casinginto the borehole without modifying the oilfield tool configuration;wherein the dynamic device traverses through the casing running tool andalters a circumferential configuration to engage an inner surface of thecasing, separating a sealant provided via the fluid supply line fromother borehole fluids.
 2. The oilfield tool of claim 1 wherein thedynamic device launching tool comprises a side entry dynamic devicelauncher.
 3. The oilfield tool of claim 1 wherein the dynamic devicelaunching tool comprises a side entry dynamic device launcher comprisingtwo or more launching portals.
 4. The oilfield tool of claim 1 whereinthe dynamic device launching tool comprises an in-line launcher.
 5. Theoilfield tool of claim 1 wherein the dynamic devices comprise expandableplugs or darts that adapt to engage the inner surface of the casing. 6.The oilfield tool of claim 1 wherein the dynamic device launching toolis located above the casing running tool.
 7. The oilfield tool of claim1 wherein the other borehole fluids comprise mud.
 8. The oilfield toolof claim 1 wherein the swivel comprises additional operationalinterfaces for operating the dynamic device launching tool.
 9. A methodfor oilfield borehole preparation comprising: configuring an oilfieldtool comprising: a casing running tool; a dynamic device launching toolmounted above the casing running tool and adapted to launch dynamicdevices; a swivel adapted to engage a fluid supply; running casing intoa borehole using the oilfield tool; cementing the casing into theborehole using the oilfield tool; wherein the dynamic devices traversevia the casing running tool and separates a sealant from other boreholefluids.
 10. The method of claim 9 wherein running the casing furthercomprises making up the casing until a desired depth is reached.
 11. Themethod of claim 9 further comprising: manipulating the casing afterrunning the casing into the borehole; wherein manipulating the casingcomprises: circulating the casing; reciprocating the casing; or rotatingthe casing.
 12. The method of claim 9 wherein cementing the casingfurther comprises: launching a first dynamic device via the dynamicdevice launching tool; introducing the sealant via the swivel; launchinga second dynamic device via the dynamic device launching tool.
 13. Themethod of claim 9 further comprising: performing a casing pressure testafter cementing.
 14. The method of claim 9 wherein the dynamic devicelaunching tool comprises a side entry dynamic device launcher.
 15. Themethod of claim 9 wherein the dynamic devices have expandablecircumferential structures configured to expand to engage an innersurface of the casing.
 16. The method of claim 9 wherein the dynamicdevice launching tool is operated via operational interfaces included inthe swivel.
 17. The method of claim 9 wherein the dynamic devicelaunching tool comprises two or more launch portals.
 18. An oilfieldsystem for running and cementing casing comprising: an oilfield toolcomprising: a casing running tool; a side entry dynamic device launchercoupled to the casing running tool and swivel and adapted to launchdynamic devices; a swivel comprising a fluid supply interface; a sealantsupply device; a borehole fluid supply device; wherein the oilfieldsystem is configured to run casing into a borehole; wherein a sealant isintroduced from the sealant supply device via the fluid supply interfacefollowing a first dynamic device traversing the casing running tool andsubsequently engaging an inner circumference of the casing; wherein aborehole fluid is introduced from the borehole fluid supply device viathe fluid supply interface following a second dynamic device traversingthe casing running tool and subsequently engaging an inner circumferenceof the casing; and wherein the first dynamic device is ruptured,providing sealant to the annulus surrounding the casing.
 19. Theoilfield system of claim 18 wherein the fluid supply interface comprisestwo or more controllable fluid inlets.
 20. The oilfield system of claim18 wherein the side entry dynamic device launcher comprises two or morelaunch portals.